MAINTE ENAN NCE AN ND TROU UBLE G MAN OTING ESHOO NUAL. Moodels E E. Self-P. Propelledd

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1 M MAINTE ENAN NCE AN ND TROU UBLE ESHOO OTING G MAN NUAL Hy-Brid Liffts Moodels HB 11030CE E HB11430CE E Self-P Propelledd Aeerial Woork Platfform

2 Table of Contents Safety... 5 Safety Symbols... 5 General Rules and Precautions... 5 Safety Guidelines... 6 Maintenance Lock... 6 Maintenance... 6 Battery Maintenance... 7 Lubrication... 8 Components requiring adjustment... 9 Examination, repair, replacement of limited life components... 9 Safety devices and systems requiring checks... 9 Storage... 9 Major Alterations or Repairs... 9 Other Procedures... 9 Setting the Tilt Sensor... 9 Voltage Test Points... 9 Stability Testing... 9 Inspection and Regular Maintenance Checklists Monthly Battery Care Prestart Inspection Checklist Frequent Inspection Checklist Pre Delivery/Annual Inspection Checklist Technical References Platform Control Error Display Hydraulic Schematic Electrical Schematic Wiring Diagrams Wiring Diagram Main Power & Safety Page 1 of 40

3 Drive Circuit Elevate/Lower Circuit Troubleshooting Troubleshooting Flowchart Troubleshooting Flowchart Drive& Steer Circuit Troubleshooting Flowchart Elevate & Lower Circuit Replacement Parts Safety and Control Decals Main Power/Safety Circuit Drive Circuit Parts Steer Circuit Parts Elevate/Lower Circuit Parts Covers/Other Warranty Revision Table: Revision A (01/14/2010): Initial Release Revision F (10/24/2012): Revised logos Page 2 of 40

4 Drive Circuit Elevate/Lower Circuit Troubleshooting Troubleshooting Flowchart Troubleshooting Flowchart Drive& Steer Circuit Troubleshooting Flowchart Elevate & Lower Circuit Replacement Parts Safety and Control Decals Main Power/Safety Circuit Drive Circuit Parts Steer Circuit Parts Elevate/Lower Circuit Parts Covers/Other Warranty Revision Table: Revision A (01/14/2010): Initial Release Revision B (04/08/2010): Revised Cover, p Part Numbers for replacement parts Revision C (06/15/2010): Revised pages 2, 3, 9 11, added p.12, revised p. 34: Added stability testing information, revised inspection checklists Revision D (07/21/2010): Revised pages 3, 15, Revision E (11/15/2010): Revised pages 3, 9 Page 3 of 40

5 Original instructions are written in English Foreword The purpose of this Maintenance Manual is to provide qualified service personnel with information for servicing and maintaining Hy-Brid Lifts. All information in this manual must be read and understood before any attempt is made to service this machine. The operation and safety manual is considered a part of the work platform and contains instructions and operating procedures essential to properly and safely operate the Custom Equipment Hy-Brid Lift. Users must read and understand all information in the Safety and Operations Manual before operation. DANGER THE OPERATION AND SAFETY MANUAL MUST BE READ AND UNDERSTOOD PRIOR TO OPERATING THE MACHINE. THE USER/OPERATOR SHOULD NOT ACCEPT OPERATING RESPONSIBILITY UNTIL THE MANUAL HAS BEEN READ AND UNDERSTOOD AS WELL AS HAVING OPERATED THE LIFT UNDER SUPERVISION OF AN EXPERIENCED AND QUALIFIED OPERATOR. BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND ALL OPERATING PERSONNEL. WARNING ANY MODIFICATION ON THIS MACHINE WITHOUT THE EXPRESS WRITTEN CONSENT OF THE MANUFACTURER IS PROHIBITED. If there is a question on application and/or operation, contact: Custom Equipment, Inc Hwy 175 Richfield, WI USA Phone: Fax: Page 4 of 40

6 Safety Safety Symbols DANGER FAILURE TO FOLLOW THIS WARNING WILL CAUSE DEATH OR PERSONAL INJURY. WARNING FAILURE TO FOLLOW THIS WARNING MAY CAUSE DEATH OR PERSONAL INJURY. CAUTION FAILURE TO FOLLOW THIS WARNING MAY CAUSE INJURY OR DAMAGE EQUIPMENT "DANGER" indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury. "WARNING" indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury "CAUTION" indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury or damage to equipment General Rules and Precautions Custom Equipment, Inc. designed the Hy Brid Lift self propelled scissor lift to be safe and reliable. It is intended for elevating personnel, along with their necessary tools and materials to overhead work locations. Vibration does not create significant hazards on this machine. An operator of any type of work platform is subject to certain hazards that cannot be protected by mechanical means. It is therefore essential that operators be competent, careful, physically and mentally fit and thoroughly trained in safe operation of this machine. Although Custom Equipment, Inc. conforms to specified EN: 280 requirements, it is the responsibility of the owner to instruct operators with the safety requirements made not only by Custom Equipment, Inc., but by the various safety boards in your area, as well as additional requirements set forth by EN: 280 If you come across a situation that you think might be unsafe, stop the platform and request further information from qualified sources before proceeding. WARNING MAINTENANCE INFORMATION IS FOR USE BY TRAINED PERSONNEL ONLY WARNING NEVER REACH BETWEEN SCISSORS LINKS OR PROP UP PLATFORM UNLESS MAINTENANCE PINS ARE IN PLACE. Page 5 of 40

7 Safety Guidelines Maintenance Lock The maintenance lock must be placed into position whenever the machine is being serviced in the raised or partially raised position. Serious injury and/or death could result if maintenance lock is not used properly. Maintenance Pin Location When in Use Figure 1: Maintenance Lock Pin Use Pin Storage Location Figure 2: Maintenance Lock Pin Storage Maintenance WARNING FAILURE TO COMPLY WITH THE LISTED SAFETY PRECAUTIONS MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH. Never work under an elevated platform until maintenance locks have been engaged. Remove all rings, watches, and jewelry when performing any maintenance. Do not wear long hair unrestrained or loose fitting clothing and neckties which may become caught on or entangled in equipment. Observe and obey all warnings and cautions on machine and in manual. Keep oil, grease, water, etc. wiped from standing surfaces and handholds. Before making any adjustments, lubricating or performing any other maintenance, shut off all power controls. Battery should always be disconnected during replacement of electrical components. Keep all support equipment and attachments stowed in their proper place. Use only approved nonflammable cleaning solvents. After maintenance, inspect the machine as described for Pre-delivery. Page 6 of 40

8 Figure 4: Battery Charger LED Display This display indicatess that power is on but there is no connection to a battery. The charger must seee approximately 5 volts on a battery to deliver d/c current. This display indicates that power is on andd that both outputs are delivering d/c current to the batteries. This display indicates that power is on and that both outputs are finished charging and are in a float maintenance mode. WARNING DO NOT OPERATE UNIT WHILE CHARGING. DO NOT DISABLE CHARGER INTERLOCK. CAUTION NEVER ADD ACID TO BATTERY! The solution is at its proper strength when the battery is manufactured. Use distilled water and keep fluid up to proper level. When required, water should be added to battery after charging, unless water level is below the plates. Lubrication Item Front Wheels Lower Slider Block Channel Specification Teflon Spray Teflon Spray Frequency of Lubrication Quarterly As needed to prevent chatter when fully loaded Page 7 of 40

9 Figure 4: Battery Charger LED Display 50% 75% 100% GEL Charger LED Display Charging State 0 to 50% charged Blinking Off Off NA 50% to 75% charged On Blinking Off NA 75% to 100% charged On On Blinking NA 100% charged On On On NA Charge for flooded type batteries NA NA NA Off Charge for Sealed type batteries NA NA NA On Abnormal Cycle Off Off Blinking NA WARNING DO NOT OPERATE UNIT WHILE CHARGING. DO NOT DISABLE CHARGER INTERLOCK. CAUTION NEVER ADD ACID TO BATTERY! The solution is at its proper strength when the battery is manufactured. Use distilled water and keep fluid up to proper level. When required, water should be added to battery after charging, unless water level is below the plates. Lubrication Item Specification Frequency of Lubrication Front Wheels Teflon Spray Quarterly Lower Slider Block Channel Teflon Spray As needed to prevent chatter when fully loaded Page 8 of 40

10 Components requiring adjustment Under normal use, no components should require adjustment. Contact the manufacturer if adjustments are required. Examination, repair, replacement of limited life components With proper use, battery maintenance, and regular inspection, there are no limited life components that require routine replacement. Safety devices and systems requiring checks Check safety functions as part of daily inspection. Check that the electromagnetic brakes are holding. Storage After periods of storage, exposure to extremes of ambient conditions heat, cold, moisture, dust etc. inspect the machine. Refer to the Pre Delivery/ Frequent Inspection Checklist in the Maintenance Manual. Major Alterations or Repairs Any alterations must be approved by the manufacturer. Major repairs, which affect the stability, strength, or performance of the machine must also be approved by the manufacturer, recorded, and include machine inspection and testing. Never attach pipe racks, material lifting devices, or make any other alteration that is not part of the intended design of the machine. Other Procedures Setting the Tilt Sensor 1. Verify that unit is powered (red or green LED illuminated/blinking). 2. Zero unit (teach unit home/level position). a. Operate tilt platform until it has reached the desired home position (level). b. Press and hold the button on top of the module for 5 seconds (both LEDs will be OFF). c. Red and Green LEDs will now FLASH. User now has 5 seconds to program d. Press and release button 3 times within 5 second period. e. Red and Green LEDs will turn on solid for 2 seconds, indicating position is being learned. Voltage Test Points Contact technical assistance for more detail. Stability Testing The HB1430CE & HB1030CE have been stability tested to standards EN280 or AS The most adverse stability test is the stationary, lateral slope configuration for both units. The overturning moment created by the test loads and forces is equivalent to a test on an unloaded machine on a level surface, as shown in the figure below. For the HB1030CE, the test weight/pull force is 52 kg/115 lb. For the HB1430CE, the test weight is 55.3 kg/122 lb. Figure 5: Stability Test, Equivalent Page 9 of 40

11 Inspection and Regular Maintenance Checklists CAUTION FAILURE TO PERFORM INSPECTIONS AND PREVENTITIVE MAINTENANCE AT RECOMMENDED INTERVALS MAY RESULT IN THE UNIT BEING OPERATED WITH A DEFECT THAT MAY RESULT IN INJURY OR DEATH OF THE OPERATOR. Regular inspection and conscientious maintenance is important to efficient economical operation of this machine. It will help to assure that equipment will perform satisfactorily with a minimum of service and repair. Make checks at the stated intervals or more frequently if required by local operating conditions. The following inspection checklists are required and included in this manual: Pre Start (Required before operation at each work shift) Monthly Battery Maintenance Frequent (Required at intervals not more than three months) Pre Delivery/Annual (Required at intervals not more than twelve months) The rated life of the machine is Light Intermittent Duty (typical use 10 years, 40 weeks per year, 20h per week, 5 load cycles per h). Monthly Battery Care WARNING THIS CHECKLIST MUST BE USED AT MONTHLY OR AFTER EVERY 100 HOURS OF USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR. MODEL NUMBER SERIAL NUMBER 1. Keep inspection records up to date. 2. Record and report all discrepancies to your supervisor. 3. A dirty machine cannot be properly inspected. Y Yes/Acceptable N No/Unacceptable R Repaired Description Y N R Monthly Battery Care: 1. Remove battery cabinet cover. 2. Remove battery caps and check fluid level. 3. Fill each cell (if needed) to split ring with distilled water. 4. Reinstall caps. 5. Wash all dirt, debris, acid, etc., off battery whenever corrosion is detected. Use a solution of 5 tsp. baking soda per quart of warm water. 6. Coat terminals with a commercially available coating. DATE INSPECTED BY Page 10 of 40

12 Prestart Inspection Checklist WARNING THIS CHECKLIST MUST BE USED AT THE BEGINNING OF EACH SHIFT OR AFTER EVERY SIX TO EIGHT HOURS OF USE. FAILURE TO DO SO COULD AFFECT THE SAFETY OF THE OPERATOR. MODEL NUMBER SERIAL NUMBER 1. Keep inspection records up-to-date. 2. Record and report all discrepancies to your supervisor. 3. A dirty machine cannot be properly inspected. Y-Yes/Acceptable N-No/Unacceptable R-Repaired Description Y N R Visual Inspections Check that there are no damaged, dented, or bent structural members. There are no loose or missing parts. Check that warning and instructional labels are legible and secure. Ensure that load capacity is clearly marked. Check the platform rails and safety gate for damage. Platform and base controls are not missing, damaged, or disconnected. Electrical cables and wires are not torn, frayed, or disconnected. Hydraulic hoses are not torn or loose, and there are no leaks. Check that hoses and the cables have no worn areas or chafing. Check the hydraulic fluid level with the platform fully lowered. Check the tires for damage. Check that wheel axle retaining rings and set screw in rear wheel are tight. Check that all snap rings are secure in grooves on pivot pins. Functional Tests Gate closes automatically and latches (alignment can be adjusted with screw on toe board or railing if necessary). Platform Controls: Check all switches and push buttons for proper operation. Emergency Stop (Stops all movement) Drive/Steer & Up/Down Mode Button (Selects drive/steer or elevate mode) Joystick & Thumb Rocker Switch (Return to neutral, drives forward & reverse, elevates & lowers) Drive Enable Trigger (Must be activated to drive) Horn Diagnostic Display (Displays tilt, overload) Base Controls: Check all switches and push buttons for proper operation. Emergency Stop (Stops all movement) Key Switch (Selects Platform Control, Ground Control, or Off) Up/Down Rocker Switch (Elevates, Lowers) Alarm (Not damaged, sounds for descent, overload) LED (Flashes when overloaded) Wheels: Front and rear wheels rotate freely. Drives in slow speed when elevated. Brakes: Machine stops when joystick released. Pothole guards deploy and lock when platform is raised. Lift does not elevate when pothole guards are blocked. DATE INSPECTED BY Page 11 of 40

13 Frequent Inspection Checklist WARNING AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED AND ADJUSTED TO MANUFACTURER'S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 3 MONTHS OR 150 HOURS, WHICHEVER COMES FIRST. MODEL NUMBER SERIAL NUMBER Check each item listed below. Use proper operating, service, and maintenance manual for specific information and settings If an item is found to be unacceptable make the necessary repairs and check the repaired box. When all items are acceptable, the unit is ready for service. Description Y N R Visual Inspections Perform all checks on the Pre Start Inspection Checklist. Inspect the condition of hydraulic fluid in reservoir. Oil should have a clear amber color. Inspect the entire machine for signs of damage, broken welds, loose bolts, or improper repairs. (Check for corrosion, cracking, abrasion, etc.) Check that all snap rings are secure in grooves on pivot pins. Check if tires are leaning in or out. Check electrical motor brushes (every 150 hours) Verify that maintenance and inspection records are up to date. Functional Tests Perform all checks on the Pre Start Inspection Checklist. Functions operate smoothly. Functions operate over full range of motion. Elevated and Lowered drive speeds do not exceed specifications listed in Operators manual. Emergency Lowering Manual override functions properly. Ground Controls override platform controls. Check that the platform does not drift down with a full load. Wheels lubricated if needed. Comments: DATE INSPECTED BY Page 12 of 40

14 Pre Delivery/Annual Inspection Checklist WARNING AERIAL PLATFORMS SHALL BE INSPECTED, SERVICED AND ADJUSTED TO MANUFACTURER'S REQUIREMENTS BY A QUALIFIED MECHANIC PRIOR TO EACH SALE, LEASE, OR RENTAL, AND EVERY 12 MONTHS. MODEL NUMBER: HB1030CE or HB1430CE SERIAL NUMBER Check each item listed below. Use proper operating, service, and maintenance manual for specific information and settings If an item is found to be unacceptable make the necessary repairs and check the repaired box. When all items are acceptable, the unit is ready for service. Check Y N R Check Y N R Base: Inspectslide tracks fordamage Steering actuator pinned All frame bolts tight Pump Secure Tie Rod secure DC motor secure Battery Hold Downs Secure Batteries Fully Charged Counterweights secured Wheels: Snap Rings Secure Wheels: Bolts/Nuts Tight Maintenance Locks: Pins in cabinet All Shields/Guards in place Hydraulic Oil Level1 from top Check all hydraulic hoses for leaks Check all hydraulic fittings for leaks Scissors: BrokenWelds BentBeam Members All rollers Turn Freely Ret. Rings Secure On Pivots Broken welds Platform: All rails in place/secure No bent rails No broken welds 110V outletsafe/working (if installed) Entrance gateclosesfreely Operator/Service Manual Included Cablesin place/secure Extendingplatform extendsfreely Extending platform Locks in StowedPosition Extending platform Locks in Extended Position Decals: Legibility Correct capacity noted Proper placement quantity Wiring: Switches secure Contactor(s) secure Tighton terminals (No loose wiring) Functions: Drive, Lift, SteerFunctioins Operational Emergency Stop Breaks Circuits Slow Speed limit switch Setproperly Emergency Down Operational Pothole guards deploy when platform Pothole interlockfunctions correctly Brakes: Operational Tilt sensorfunctional Warning Horn Alarms Motion Alarms Functional Hour meteroperational Battery indicationoperational Verify Overload Calibration Battery ChargerSecure/Operational Comments: DATE INSPECTED BY Page 13 of 40

15 Technical References Platform Control Error Display Display Description 01 System initialization error 02 System communication error 03 Invalid option setting 11 Free wheel switch on motor is open 12 Chassis Up or Down ON at power up 18 Pothole guard error 31 Pressure Sensor Fault 32 Angle Sensor Fault 42 Platform Left Turn Switch ON at power up 43 Platform Right Turn Switch ON at power up 46 Platform Joystick Enable Switch ON at power up 47 Platform Joystick not in neutral at power up 54 Lift Up Coil Fault 55 Lift Down Coil Fault 58 Brake Fault 60 Motor Fault 61 Motor Controller Fault 62 Temperature Fault 63 Charger Fault 64 Motor Controller Fault 68 Low Voltage Fault 80 Over 80% Load 90 Over 90% Load 99 Over 100% Load OL Overloaded Platform LL Machine Tilted beyond safe limits Platform Control Battery Monitor Display Battery Percent Description 90 Percent of Battery Charge 70 Percent of Battery Charge 50 Percent of Battery Charge 30 Percent of Battery Charge 20 Charge Battery 10 Very Low Charge Page 14 of 40

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28 Does the machine have any function: (Drive, Steer Elevate/Lower) No Are the batteries connected? Check per wiring diagram. Yes Is master disconnect switch open? Yes Is key switch turned on No No Yes, but some function(s) are not working properly Connect batteries. See wiring diagram & battery connection sequence. Close Switch. Turn key switch on Does Platform Control Display a Fault Code? Are the batteries fully charged? Yes Is short protection fuse at pump blown? Check Component or Condition Referenced by Fault Code No (Check voltmeter at lower control or check voltage across battery terminals using voltmeter/multi-meter) Charge batteries. Yes Replace Fuse If batteries do not take charge Replace batte Or Replace char (Load test batteries, individually, dis See Drive & Steer Problems Flowchart See Elevating & Lowering Problems Flowcharts Is there a different problem? Contact CEI for further troubleshooting Page 27 of 40

29 ? Are both E-Stop buttons Is Upper Control Yes Yes Yes off? plugged in? Is charger plugged in? No No Yes Reset E-Stop buttons. Pull out at both upper control and lower control locations. Connect Upper Control box. Unplug charger. Unit will not operate while charging. No Yes Is unit overloaded? No Yes Check for loose wiring connections. Check for ground connection at pump. See wiring diagrams. Check for continuity in connections use Voltmeter/ Multi-meter at 400V setting. Remove load. Safety function activated. ries ger connected from machine) Still no functions? Contact CEI for further troubleshooting Consider Signet charger failure (interlock contacts) Hy-Brid Troubleshooting Flowchart Revision A: Initial Release 01/14/2010 Page 28 of 40

30 Does the machine drive? (Elevate, Lower OK) Is either or two brakes manually released? No Is either of two brake switches damaged or disconnected? No Is drive unit damaged? Yes Yes Yes Yes, but not properly Check connections at both pump and board. See wiring diagrams. Flip brake handle(s) at rear of machine to engage brakes. Replace brake switch. Note that brake limit switch tabs are delicate. Use caution not to break off. Replace drive unit Driving slowly? Are batteries fully charged? No Charge Batteries Drives slow when lowered? Is mode limit switch damaged or blocked with debris? Yes Che Drives fast when elevated? Do pothole guards and lock deploy properly? Yes Is mode limit switch damaged or blocked with debris? Clean any debris from pothole arm mechanism Does not drive when elevated? Is machine tilted? (Tilt sensor will be beeping, but functions should not be disabled) Is machine overloaded? (Safety feature stops all function if overloaded) Drives intermittently? Check wiring connection integrity. Is there moisture or corrosion in any connections? Does not Steer? Consider relay failure, relay block wiring. Check wire connections at actuator. Pull test connections if failure, crimp on new connector(s) Page 29 of 40

31 No Are all connections to drive control board secure? Yes Is there moisture or corrosion in any connections? No Replace drive control board No Yes Still no drive? Reconnect Allow to dry for 24 hours and try again. Board probably will need replacement. Apply dielectric grease to connectors at main wire harness. Contact CEI for further troubleshooting. Consider brake damage, broken joystick handle (drive enable), bad hour meter, loose connections in lower and upper control Clean any debris from limit switch area. ck for proper connection inside limit switch. (See wiring diagram). Replace mode limit switch. Contact CEI for further troubleshooting. Consider board failure or incorrect wiring. Yes Clean any debris from limit switch area. Check for proper connection inside limit switch. (See wiring diagram). Replace mode limit switch. Contact CEI for further troubleshooting. Consider board failure or loose wiring. Remove load. Contact CEI for further troubleshooting. Consider board failure, pothole interlock limit switch failure, control module failure failure, disconnected, damaged, or failed height transducer. Air dry all connections and try again. Board probably will need replacement. Apply dielectric grease to connectors at cable. Contact CEI for further troubleshooting. Consider board failure Check steer actuator for failure. Apply 24V to actuator leads. Check joystick thumb switch Hy-Brid Troubleshooting Flowchart Drive & Steer Problems Revision A: Initial Release 01/14/2010 Page 30 of 40

32 Does machine raise/ lower? No Does pump operate? Yes Is emergency down valve open? Is hydraulic fluid No Check for power connection. See Hy-Brid Troubleshooting Close emergency down valve or cable connections With platform lowe pump reservoir to 1 top of reservo Is power solenoid damaged? Replace solenoid. Yes, but not properly Are diodes functioning properly? Measure resistance across diode Ohm meter/multi-meter at 40 kω Replace pump assembly Ascent speed slow or erratic? Are any structural members bent? Is battery fully charged? Is emergency down valve open? I Contact manufacturer to arrange replacement. Charge battery. Close emergency down valve. R Starts elevating, then stops? Are pothole guards blocked? Is pothole limit switch functionning? Replace limit switch or repair connections. Remove obstruction. Will not descend? Has key switch been turned off? Is an E-Stop activated? Is battery charged? Turn key to on position. Pull out emergency stop button at upper and lower controls. Charge batteries. Creeps down? Is emergency down valve open? Foreign matter lodged in up or down valve? Faulty down valve? Electrical problem? Disassemble and clean. Look for residue in screen and on O-ring or damage to O-ring. Disconnect coil. Check if unit s drifting. Check voltage at coil s be 0 V when not energized. Close emergency down valve. Check cable connections. Replace down valve. Run unit up an Might be able to walls inside cylin Page 31 of 40

33 low? Is down valve stuck open? Is up/down switch damaged? Contact CEI for further troubleshooting. red, fill " below ir Flush valve by simultaneously pressing up switch at base and down switch on platform control for 30 sec. Replace rocker switch at upper or lower control. setting. With black lad on stripe side and red on other side, should get a resistance reading. Switch leads, no reading. Replace bad diode. s there a restriction in hydraulic hose? Flush down valve by simultaneously pressing up switch at base and down switch on platform control for 30 sec. There may be foreign matter lodged. Check integrity of electrical connections, There may be a loose connection or momentary short. Replace pump. May be worn or defective. eplace hydraulic hose. Replace down solenoid. Check for loose electrical connections. Damaged cylinder or damaged seal in cylinder? Coil mounting nut too tight? Faulty check valve in pump? tops hould Nut should only be lightly snug: 30 in.-lb. Replace coil and lightly tighten nut. d then check for oil flow out of return line. Bad cylinder seal if oil is flowing from return line. repair with seal kit;, probably need to replace cylinder. If der are scratched or pitted, cylinder needs replacement. Listen carefully near motor when not energized may be running backwards. Replace pump SUPO-611e Hy-Brid Troubleshooting Flowchart Elevate & Lower Problems Revision A: Initial Release 01/14/2010 Page 32 of 40

34 Replacement Parts CAUTION USE ONLY MANUFACTURER APPROVED REPLACEMENT PARTS. USE OF NON OEM PARTS WILL VOID WARRANTY. DANGER REPLACEMENT OF THE FOLLOWING COMPONENTS WILL AFFECT THE STRENGTH, STABILITY, OR SAFETY FUNCTION OF THE UNIT: BATTERY (ELEC 047), HYDRAULIC CYLINDER (HYDR OR HYDR 041 2), DRIVE CONTROL BOARD (ELEC 903), AND ALL STRUCTURAL COMPONENTS. Listed below are replacement parts that may be available and listed for reference. These represent current revisions. Refer to our website, for more complete part listings and earlier revisions. Several parts are model, serial number, or manufacture date specific. Contact your dealer for replacement part availability and pricing. Safety and Control Decals Refer to Operator s Manual for decal part numbers and locations. Page 33 of 40

35 Main Power/Safety Circuit Item # (Not Pictured) (Not Pictured) Description B+ Power Connection Location on Pump Fuse B Ground Connection Location on Pump Battery Battery Tray Battery Strap Master Power Switch Tilt Sensor Battery Charger Control Module Emergency Stop Switch Tilt Alarm Key Switch Spare Key Main Wire Harnesss Emergency Stop Switch Joystick Control Module, Upper Upper Control Assembly Lower Control Assembly Battery Charger Cord Battery Cables Part # NA ELEC NA (ELEC 047) HB 0001 P HARD 054 ELEC 633 KIT ELEC ELEC 829 ELEC 747 SUBA8350E ELEC 071 KIT ELEC ELEC 073E ELEC 073EKEY SUB A13006E ELEC 071 KIT ELEC SUB A9350E SUBA9003E SUB A8003E ELEC ELEC & Page 34 of 40

36 Drive Circuit Parts Item # Part # Description 1 ELEC 626 3R Electric Drive Motor (Right/Control Side) 2 ELEC Brake Micro switch 3 ELEC 627 3R Brake (Left) 4 ELEC 627 3L Brake (Right) 5 SUBA9003E Platform Control Assembly 6 ELEC 626 3L Electric Drive Motor (Left/Control Side) 7 WHEE x 4 Wheel 8 SUBA8350E Base Control Module 9 SUB 904 Drive Control Board (specific to this model/series only) 10 ELEC Hour Meter Page 35 of 40

37 Steer Circuit Parts Item # Part # Description 1 HB ST 2 A P Tie Rod Long 2 PB 0018 P Center Steer Pin 3 HB ST 4 B PC Center Steer Weldment 4 PB 0021 P Caster 5 HB ST 3 A P Tie Rod Short 6 SUB A9003E Platform Controls Assembly 7 SUBA8350E Lower Control Module 8 SUB A29 KIT Steer Actuator Assembly 9 ELEC 631 Relay 10 ELEC 624 Limit Switch 11 WHEE X 2 WHEEL (Not Pictured) (No Part #) 7A ACG Fuse Page 36 of 40

38 Elevate/Lower Circuit Parts Page 37 of 40

39 Item # Part # Description 1 HB PH 21 R PC HB2 Pothole Bar R (For 10 Front Wheel Models) 2 HYDR 050 1E Hydraulic Pump (Not Pictured) (HYDR 032) Hydraulic Fluid Not available as a replacement part. Replace with Flomite #150, Dexron II, Mobil DTE 2, or equivalent. 3 HB ML P Maintenance Lock Pin 4 (Varies by Model) Hydraulic Cylinder (For 10 Models) Hydraulic Cylinder (For 14 Models) 5 ELEC 647 Angle Transducer 6 HARD 644 HARD E Down Cable (1430) E Down Cable (1030) 7 ELEC 829 Tilt Sensor 8 SUB A8305E Lower Control Module (Not Pictured) ELEC Beeper 9 HB PH 21 L PC HB2 Pothole Bar L (For 10 Front Wheel Models) 10 ELEC 071 KIT E Stop 11 ELEC 133B Rocker Switch 12 HYDR 665 Up Valve 13 HYDR V Coil Pump Mount Plate 15 HYDR V Solenoid 16 HYDR 044 FL3 Hirschmann Connector w/suppression Diode 17 LAS M115 E Down Valve Actuator 18 WHEE 605 Spacer 19 HARD 650 1/16 Shaft Collar 20 HYDR 007 2E Down Valve & Coil 21 (Varies by Model) Hydraulic Hose HYDR 600 or HYDR HYDR 626 Flow Control 23 SUBA003E Upper Control Assembly 24 HB PH 7 P PH Lock Weldment 25 LAS M220 P Pothole Arm 26 ELEC Limit Switch 27 LAS M222 P Limit Switch Plate 28 ELEC Limit Switch PH Pick Up Arm 30 HB PH 13 Guide Block 31 HB PH 20 Pothole Guard Actuator 32 HARD 072 Spring 33 ELEC 648 Pressure Transducer Page 38 of 40

40 Covers/Other Item # Part # Description 1 LAS M231 PC Cover, Front 2 LAS M246 PC Cover, Pump Side 3 LAS M230 PC Cover, Rear 4 LAS M226 PC Cover, Battery, Control Side 5 HARD 633B Cabinet Latch Handle 6 HARD 633C or Cabinet Latch Cam HARD 633E 7 SUB A8003E Lower Control Assembly Page 39 of 40

41 Warranty LIMITED WARRANTY Warranty Statement --Outside North America Custom Equipment, Inc. (the Company ) warrants that all new units of equipment manufactured and sold by it conform to the Company s latest published specifications. Also, that all purchased components and sub-assembled parts and assemblies shall be free from defect in material and/or workmanship for a period of 24 months from the date a new unit is placed into service, with the exception of batteries which are covered by the battery manufacturer for a period of ninety (90) days (pro-rated for one (1) year) on batteries. Further, that all structural components manufactured, purchased, and installed by Custom Equipment, Inc. shall be free of any defect in material and/or workmanship for a period of 60 months from the date a new unit is placed into service. If the equipment owner/end-user experiences a failure or deficiency within the specified warranty period they must promptly notify an authorized Dealer service repair facility. Custom Equipment s warranty policy requires that ALL warranty claims parts be held for inspection for up to six months or returned to us in a timely fashion if requested. Parts will be requested when we will be returning these parts to our vendor fore credit. During the Warranty period, Custom Equipment, Inc. reserves the right to replace, repair, exchange, or to provide a new, used, or rebuilt component, assembly, sub-assembly, or weldment at their discretion, dependent upon circumstance, situation, and/or availability. For battery warranty, call the number listed on the battery for further instructions. This Warranty Policy does NOT cover damage caused by; shipment, misuse of unit (includes operation beyond Factory established limits, loads, and/or specifications), failure to properly service and maintain the unit in accordance with the Company s manuals or Factory Service Bulletins. Custom Equipment, Inc. DOES NOT accept any responsibility for alterations or modifications to the unit, or, damages caused by any natural disasters (such as fire, flood, wind and lightning). THE PREVIOUS WARRANTY STATEMENT IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. In no event shall the Company be liable for any indirect, incidental, consequential, or special damage (including without limitation to loss of profits, loss of revenue, cost of capital, cost of substitute equipment, downtime, examination fees, claims of third parties, and injury to person or property) based upon any claim of breach of warranty, breach of contract, negligence, strict liability in tort, or any other legal theory. This limited warranty statement recognizes the risks and limitations of product failure between Custom Equipment, Inc. and the Buyer. This written warranty is also understood to be the complete and exclusive agreement between the parties, superseding all prior agreements, oral or written and all other communications between the parties relating to the subject matter of this warranty. No employee, agent or distributor of the Company, or any other person is authorized to state or imply any additional warranties on behalf of the Company, nor assume for the Company any other liability in connection with any of its products, unless made in writing, dated, and signed by an officer of the Company. Page 40 of 40